液压冲床主要结构设计优化及实验研究
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摘要
压力机作为一种不可或缺的设备在基础工业的各个领域扮演着极其重要的角色。本课题研究的精密液压冲床是液压机中的新产品。
作为压力机主流机身形式之一的开式机身,工作台在三个方向都是敞开的,因此方便操作。但开式压力机工作时变形大,刚性较差,这将直接影响到零件加工精度。如何优化床身结构,提高开式压力机床身的刚度,同时又能降低床身的结构重量,对于开式压力机床身设计尤为重要。本文通过有限元软件COSMOS对开式液压机的机身进行优化,得出了一系列的优化尺寸。并对墙板的过渡形线进行改进,尝试分别使用双圆弧形线和椭圆形线。根据墙板剪切应变带的分布,尝试性提出自补偿开式机身的改进结构。
预应力结构广泛应用于工业的各个领域,是一种可以提高结构承载能力的先进设计方法。残余应力可以部分抵消工作时的工作应力,从而提高结构的强度;另一方面也改变了循环应力比,从而提高疲劳寿命。本文对油缸的缸底进行了应力分析。对焊接缸底尝试提出过盈配合的预应力形式。通过保守的疲劳分析比较不同过盈量的缸底寿命安全系数的区别,得出具体的过盈配合实施方案。对缸底进一步改进,在缸底增加卸荷槽。并使用Matlab遗传算法工具箱对缸底进行优化计算。
为了验证分析结果的可行性,本文使用了传感器、放大电路、NI数据采集卡及LabView等构建了应变测量系统。使用相似原理制作了墙板模型,对模型的应变进行了测量。测量结果与理论结果比较吻合。证明了本文有限元的分析方法及结果是可行的。
As one kind of indispensable equipment, press plays very important part in each area of the basic industry .Precision hydraulic punch in our subject is one kind of new hydraulic press product.
C-type frame is one kind of mainstream press frame. Three aspects of its table are open. So it is facility for people to operate. But the frame's deformation is big, the stiffness is small. It'll affect the precision of the workpiece. It is very important to optimize the frame structure of the press, enhance the stiffness of the frame，at the same time reduce the mass of the frame. In this dissertation, the frame of the press is optimized by FEA software COSMOS. A series optimized dimensions of the frame is got. The transition curve of the side plate is improved. Double arc curve and ellipse curve are tried as the transition curve. According to the distribution of the shear strain area, self compensate frame is attempted as the improvement of the frame.
Prestressed structure is widely used in each field of the industry. It is one kind of advance design method which can enhance the carrying capacity of the structure. Residual stress can partly counteract the working stress, so that the strength of the structure is enhanced. On the other hand, the cycle stress ratio is changed, so the fatigue life also becomes longer. In this dissertation, the stress of the hydraulic cylinder bottom is analyzed. Using of the interference fit in the welded cylinder bottom is attempted. Fatigue life safety factor of various interference fit structures is compared by conservative fatigue analyze. Specific interference fit idea is got. The structure of the hydraulic cylinder is further improved. Unloading groove is used in the cylinder bottom. The cylinder bottom is optimized calculating by Matlab Genetic Algorithm toolbox.
For validating the feasibility of the analyze result, here use the sensor, amplification circuit, NI data acquisition card and Labview to construct the measurement system. Use Similarity theory to make a model of the side plate. Measure the strain of the model. The result of the experiment is in accordance with the theoretical prediction. It improves the method and the result in this dissertation by FEM is feasibility.
作为压力机主流机身形式之一的开式机身,工作台在三个方向都是敞开的,因此方便操作。但开式压力机工作时变形大,刚性较差,这将直接影响到零件加工精度。如何优化床身结构,提高开式压力机床身的刚度,同时又能降低床身的结构重量,对于开式压力机床身设计尤为重要。本文通过有限元软件COSMOS对开式液压机的机身进行优化,得出了一系列的优化尺寸。并对墙板的过渡形线进行改进,尝试分别使用双圆弧形线和椭圆形线。根据墙板剪切应变带的分布,尝试性提出自补偿开式机身的改进结构。
预应力结构广泛应用于工业的各个领域,是一种可以提高结构承载能力的先进设计方法。残余应力可以部分抵消工作时的工作应力,从而提高结构的强度;另一方面也改变了循环应力比,从而提高疲劳寿命。本文对油缸的缸底进行了应力分析。对焊接缸底尝试提出过盈配合的预应力形式。通过保守的疲劳分析比较不同过盈量的缸底寿命安全系数的区别,得出具体的过盈配合实施方案。对缸底进一步改进,在缸底增加卸荷槽。并使用Matlab遗传算法工具箱对缸底进行优化计算。
为了验证分析结果的可行性,本文使用了传感器、放大电路、NI数据采集卡及LabView等构建了应变测量系统。使用相似原理制作了墙板模型,对模型的应变进行了测量。测量结果与理论结果比较吻合。证明了本文有限元的分析方法及结果是可行的。
As one kind of indispensable equipment, press plays very important part in each area of the basic industry .Precision hydraulic punch in our subject is one kind of new hydraulic press product.
C-type frame is one kind of mainstream press frame. Three aspects of its table are open. So it is facility for people to operate. But the frame's deformation is big, the stiffness is small. It'll affect the precision of the workpiece. It is very important to optimize the frame structure of the press, enhance the stiffness of the frame，at the same time reduce the mass of the frame. In this dissertation, the frame of the press is optimized by FEA software COSMOS. A series optimized dimensions of the frame is got. The transition curve of the side plate is improved. Double arc curve and ellipse curve are tried as the transition curve. According to the distribution of the shear strain area, self compensate frame is attempted as the improvement of the frame.
Prestressed structure is widely used in each field of the industry. It is one kind of advance design method which can enhance the carrying capacity of the structure. Residual stress can partly counteract the working stress, so that the strength of the structure is enhanced. On the other hand, the cycle stress ratio is changed, so the fatigue life also becomes longer. In this dissertation, the stress of the hydraulic cylinder bottom is analyzed. Using of the interference fit in the welded cylinder bottom is attempted. Fatigue life safety factor of various interference fit structures is compared by conservative fatigue analyze. Specific interference fit idea is got. The structure of the hydraulic cylinder is further improved. Unloading groove is used in the cylinder bottom. The cylinder bottom is optimized calculating by Matlab Genetic Algorithm toolbox.
For validating the feasibility of the analyze result, here use the sensor, amplification circuit, NI data acquisition card and Labview to construct the measurement system. Use Similarity theory to make a model of the side plate. Measure the strain of the model. The result of the experiment is in accordance with the theoretical prediction. It improves the method and the result in this dissertation by FEM is feasibility.
引文
[1]张祖芳.开式压力机机身的有限元分析及其优化设计[硕士学位论文].南京:东南大学,2004
[2]机械压力机的基础知识(第一版)杨群译.北京:电子工业出版社,1990.6.30-37
[3]刘振堂.国外数控冲床的现状和发展趋势.锻压机械,2002,(1),7-9
[4]臧贻娟.数控高速冲床液压系统设计及仿真[硕士学位论文].山东济南:山东大学.2006
[5]俞新陆.液压机的设计与应用(第一版).北京:机械工业出版社,2007.4
[6]Y.H.Song,Y.N.Yan,R.J.Zhang Finite element analysis of the prestress wire-winding press.Journal of Materials Processing Technology.2004.151.255-257
[7]M.Arentoft,M.Eriksen,T.Wanheheim.Determination of six stiffnesses for press[J].Journal of Materials Processing Technology 105(2000)246-252
[8]M.Neumann,H.Hahn.Computer simulation and dynamic analysis of a mechanical press based on different engineer models[J].Methematics and Computer in Simulation 46(1998)559-574
[9]郑幕侨,冯崇植,蓝祖佑.坦克装甲车辆.(第一版).北京:北京理工大学出版社,2003.110-111
[10]林峰,颜永年,吴任东等.现代重型模锻液压机的关键技术.机械工程学报,2006,42(3):9-14
[11]赵长财,孙惠学,袁荣娟等.ZC型液压缸的研究.钢铁,1998,33(4)
[12]姚保森.我国板冲压液压机的现状及发展.锻压装备与制造技术,2007,42(02):22-24
[13]陈绍蕃.钢结构设计原理(第三版).北京:科学出版社,2006.2.65-66
[14]S.SURESH.Fatigue of Materials.Cambridge:Cambridge University Press,1991.8-13
[15]夏志斌,姚谏.钢结构设计例题集(第一版).北京:中国建筑工业出版社,1994.9.334-337
[16]孔志礼,陈良玉.实用机械可靠性设计理论与方法(第一版).北京:科学出版社,2003.7.81-82
[17]John M.Barsom,Stanley T.Rolfe.Fracture & Fatigue Control in Structures(第二版).USA:Prentice-Hall,Inc.1987
[18]《机械设计手册》编委会.机械设计手册:单行本.疲劳强度设计(第四版).北京:机械工业出版社,2007.7 46-47
[19]A.Buch.Fatigue Strength Calculation.USA:TRANS TECH PUBLICATIONS.1985.136-137
[20]李海梅,宋刚,刘永志.金属材料疲劳极限的估算.郑州大学学报,2002,43(4):26-29
[21]丁遂栋.结构钢光试样非对称循环疲劳极限的估算.机械强度,1997,19(1):45-47
[22]Thomas H.Courtney Mechanical Behavior of Materials[美].北京:机械工业出版社.2004.577-578
[23]George E.Dieter[美].Mechanical Metallurgy(Third Edition)(第一版)北京:清华大学出版社,2006.384-385
[24]周传月,郑红霞,罗慧强等.MSC.Fatigue疲劳分析应用与实例(第一版).北京:科学出版社,2005.25-26
[25]Pan Ziwei,Shao Weixun,Wang Biao.Finite-element analysis of Bottom Box Beam of 80MN Hydraulic Press.J.of Anhui University of Technology 2005,22(2):145-146
[26]林道盛,杨雨??,曹桂荣.锻压机械及其有限元计算(第一版).北京:北京工业大学出版社,1998.139-143
[27]江洪,陈燎,王智.SolidWorks有限元分析实例解析(第一版).北京:机械工业出版社,2007.1-2
[28]何强,张大可,赵万军.法兰支承液压缸的应力计算及讨论.机械,2007,34(3):15-17
[29]孙彩丽.20MN快锻液压机设计及整体工作性能分析[硕士学位论文].河北秦皇岛:燕山大学.2007
[30]张仁杰.液压缸的设计制造和维修(第一版).北京:机械工业出版社,1989.6.52-55
[31]赵应樾.常用液压缸与其修理(第一版).上海:上海交通大学出版社,1996.98-128
[32]A.P.博雷西,O.M.赛德博坦,F.B.西利,J.O.史密斯.高等材料力学[中译文]/(美)(第一版).汪一麟,汪一骏译.北京:科学出版社.1987.2.444-472.
[33]Richard G.Budynas,Advanced Strength and Applied Stress Analysis(Second Edition),北京:清华大学出版社,2001.348-357
[34]雷英杰,张善文,李续武等.遗传算法工具箱及应用(第一版).西安:西安电子科技大学出版社,2005.146
[35]王刚,王琼梅.配重不足时结构试验模型与原型的相似关系.工业建筑,2007,第37卷(第9期):67-68
[36]高为宫.轧机扭矩监测中的数据采集与无线数传技术研究[硕士学位论文].华中科技大学,2005
[37]康鲁杰,杨继红.电阻应变片的选用.科技应用.2004,第33卷第六期:9-10
[38]耿皓,李建华.应力应变电测技术中影响测量误差的主要因素分析.物流科技,2005.3,第28卷(总第117期):98-100
[39]方昌林,徐刚.电气测量仪器.(第一版).北京:化学工业出版社,2006.4.84-85
[40]郭怀天,李宝华,赵玉侠等.基于电阻应变式传感器的电子天平的研制.微计算机信息,2007,第23卷(第6-1期):140-142
[41]唐文炳.电子衡器使用与维修.(第一版).北京:中国计量出版社,2003.8.50-53
[42]候国屏,王坤,叶齐鑫.Labview7.1编程与虚拟仪器设计.(第一版).北京:清华大学出版社,2005.2,1-2
[43]雷振山,赵晨光,魏丽等.Labview8.2基础教程.(第一版).北京:中国铁道出版社,2008,159-160
[2]机械压力机的基础知识(第一版)杨群译.北京:电子工业出版社,1990.6.30-37
[3]刘振堂.国外数控冲床的现状和发展趋势.锻压机械,2002,(1),7-9
[4]臧贻娟.数控高速冲床液压系统设计及仿真[硕士学位论文].山东济南:山东大学.2006
[5]俞新陆.液压机的设计与应用(第一版).北京:机械工业出版社,2007.4
[6]Y.H.Song,Y.N.Yan,R.J.Zhang Finite element analysis of the prestress wire-winding press.Journal of Materials Processing Technology.2004.151.255-257
[7]M.Arentoft,M.Eriksen,T.Wanheheim.Determination of six stiffnesses for press[J].Journal of Materials Processing Technology 105(2000)246-252
[8]M.Neumann,H.Hahn.Computer simulation and dynamic analysis of a mechanical press based on different engineer models[J].Methematics and Computer in Simulation 46(1998)559-574
[9]郑幕侨,冯崇植,蓝祖佑.坦克装甲车辆.(第一版).北京:北京理工大学出版社,2003.110-111
[10]林峰,颜永年,吴任东等.现代重型模锻液压机的关键技术.机械工程学报,2006,42(3):9-14
[11]赵长财,孙惠学,袁荣娟等.ZC型液压缸的研究.钢铁,1998,33(4)
[12]姚保森.我国板冲压液压机的现状及发展.锻压装备与制造技术,2007,42(02):22-24
[13]陈绍蕃.钢结构设计原理(第三版).北京:科学出版社,2006.2.65-66
[14]S.SURESH.Fatigue of Materials.Cambridge:Cambridge University Press,1991.8-13
[15]夏志斌,姚谏.钢结构设计例题集(第一版).北京:中国建筑工业出版社,1994.9.334-337
[16]孔志礼,陈良玉.实用机械可靠性设计理论与方法(第一版).北京:科学出版社,2003.7.81-82
[17]John M.Barsom,Stanley T.Rolfe.Fracture & Fatigue Control in Structures(第二版).USA:Prentice-Hall,Inc.1987
[18]《机械设计手册》编委会.机械设计手册:单行本.疲劳强度设计(第四版).北京:机械工业出版社,2007.7 46-47
[19]A.Buch.Fatigue Strength Calculation.USA:TRANS TECH PUBLICATIONS.1985.136-137
[20]李海梅,宋刚,刘永志.金属材料疲劳极限的估算.郑州大学学报,2002,43(4):26-29
[21]丁遂栋.结构钢光试样非对称循环疲劳极限的估算.机械强度,1997,19(1):45-47
[22]Thomas H.Courtney Mechanical Behavior of Materials[美].北京:机械工业出版社.2004.577-578
[23]George E.Dieter[美].Mechanical Metallurgy(Third Edition)(第一版)北京:清华大学出版社,2006.384-385
[24]周传月,郑红霞,罗慧强等.MSC.Fatigue疲劳分析应用与实例(第一版).北京:科学出版社,2005.25-26
[25]Pan Ziwei,Shao Weixun,Wang Biao.Finite-element analysis of Bottom Box Beam of 80MN Hydraulic Press.J.of Anhui University of Technology 2005,22(2):145-146
[26]林道盛,杨雨??,曹桂荣.锻压机械及其有限元计算(第一版).北京:北京工业大学出版社,1998.139-143
[27]江洪,陈燎,王智.SolidWorks有限元分析实例解析(第一版).北京:机械工业出版社,2007.1-2
[28]何强,张大可,赵万军.法兰支承液压缸的应力计算及讨论.机械,2007,34(3):15-17
[29]孙彩丽.20MN快锻液压机设计及整体工作性能分析[硕士学位论文].河北秦皇岛:燕山大学.2007
[30]张仁杰.液压缸的设计制造和维修(第一版).北京:机械工业出版社,1989.6.52-55
[31]赵应樾.常用液压缸与其修理(第一版).上海:上海交通大学出版社,1996.98-128
[32]A.P.博雷西,O.M.赛德博坦,F.B.西利,J.O.史密斯.高等材料力学[中译文]/(美)(第一版).汪一麟,汪一骏译.北京:科学出版社.1987.2.444-472.
[33]Richard G.Budynas,Advanced Strength and Applied Stress Analysis(Second Edition),北京:清华大学出版社,2001.348-357
[34]雷英杰,张善文,李续武等.遗传算法工具箱及应用(第一版).西安:西安电子科技大学出版社,2005.146
[35]王刚,王琼梅.配重不足时结构试验模型与原型的相似关系.工业建筑,2007,第37卷(第9期):67-68
[36]高为宫.轧机扭矩监测中的数据采集与无线数传技术研究[硕士学位论文].华中科技大学,2005
[37]康鲁杰,杨继红.电阻应变片的选用.科技应用.2004,第33卷第六期:9-10
[38]耿皓,李建华.应力应变电测技术中影响测量误差的主要因素分析.物流科技,2005.3,第28卷(总第117期):98-100
[39]方昌林,徐刚.电气测量仪器.(第一版).北京:化学工业出版社,2006.4.84-85
[40]郭怀天,李宝华,赵玉侠等.基于电阻应变式传感器的电子天平的研制.微计算机信息,2007,第23卷(第6-1期):140-142
[41]唐文炳.电子衡器使用与维修.(第一版).北京:中国计量出版社,2003.8.50-53
[42]候国屏,王坤,叶齐鑫.Labview7.1编程与虚拟仪器设计.(第一版).北京:清华大学出版社,2005.2,1-2
[43]雷振山,赵晨光,魏丽等.Labview8.2基础教程.(第一版).北京:中国铁道出版社,2008,159-160